Category Archives: LED Manufacturing

Dramatically falling costs and improvements in efficiency are driving increased sales of light emitting diode (LED) lamps for street lighting. Costs have fallen as much as 50% over the past two years and are expected to continue falling. By 2015, LEDs will become the second-leading type of lamp for street lights in terms of sales, behind only high pressure sodium lamps, according to a new report from Pike Research, a part of Navigant’s Energy Practice. By 2020, the study concludes, LED lamps for street lights will generate more than $2 billion in annual revenue.

“Broader investments in smart city infrastructure by municipal governments will boost smart street lighting projects, as the two go hand in hand,” says research analyst Jesse Foote. “Smart street lighting systems can provide a backbone for other smart city applications, and conversely, a city investing in networking capabilities for smart city applications should also be looking to include better management of street lighting.”

Nearly all smart street lighting projects are still in a pilot phase at the moment, according to the report. The adoption of LED street lights and networked control systems is seriously hindered by the ownership models and tariff structures in place across the United States and in some European and Asian locations as well. If utility companies own street lighting systems and charge a fixed tariff per light to municipalities, then towns have little financial incentive to pay for upgrading their lights. However, the potential for significant energy savings, reduced emissions and improved quality of service, combined with falling LED prices, means that more and more cities will find this an attractive proposition over time.

The report, Smart Street Lighting, analyzes the global market opportunity for lamp upgrades and networked lighting controls across five categories of public outdoor lighting: highways, roads, parking lots, city parks, and sports stadiums. The report provides a comprehensive assessment of the demand drivers, obstacles, policy factors, and technology issues associated with the growing market for street lighting controls. Key industry players are profiled in depth and worldwide revenue and capacity forecasts, segmented by lamp type and region, extend through 2020.

 

The way the world is lit up could be revolutionized by a new European-wide research project being led by the University of Dundee.

The 11.8 million Euros NEWLED project aims to develop a new generation of white light-emitting LED lights, which would be much more efficient than existing light bulbs.

It is estimated that efficient white-light LEDs, if successfully developed and widely implemented, could have a massive effect on reducing global energy consumption and C02 emissions.

"Common lightbulbs have a pretty low efficiency rating and even the best current white LEDs in use only have an overall efficiency of around 25%," said Professor Edik Rafailov, NEWLED project leader based in the School of Engineering, Physics and Mathematics at Dundee. "What we are aiming to develop is a significantly more efficient white LED, which would be around 50-60% efficient. If we can do that and it becomes widely adopted, then the effects on energy consumption would be enormous. It would also produce lighting over which much more control could be exercised in brightness and tone."

NEWLED brings together academic and industrial partners and is funded through the European Union’s FP7 program.

The effort to produce highly efficient white LEDs will see the project examine every stage of the LED fabrication process, from developing new knowledge on the control of semiconductor properties on a near-atomistic level to light mixing and heat management.

By examining the entire process, NEWLED aims to ensure that the new LEDs will be well adjusted to avoid compromising the achievements of the overall process and to ensure significant system and operating cost reduction.

Production system from AIXTRONAIXTRON SE today announced that, in the third quarter of 2012, long-term customer Formosa Epitaxy Inc. (FOREPI), Taiwan, placed a new order for multiple CRIUS II-L MOCVD production systems in a 69×2-inch configuration. All systems will be used for the manufacturing of ultra-high brightness (UHB) GaN-based blue and white LEDs.

AIXTRON’s local service team has started installing and commissioning the new systems in the fourth quarter of 2012 at FOREPI’s new state-of-the-art factory in the Pin-Jen industrial zone, Taiwan. Delivery will be completed in the second quarter of 2013. In May 2012, FOREPI had already purchased several CRIUS II-XL and AIX G5 HT reactors.

“This new order reflects our on-going satisfaction with AIXTRON’s products,” comments FOREPI’s chairman Dr. Frank Chien. “AIXTRON has proven itself as an excellent partner, providing superior customer care by responding to our requests and delivering the needed solutions. With short time-to-production, and highest performance and throughput, AIXTRON’s latest MOCVD generations meet the specific challenges of larger wafers and maximum chip yields.”

All CRIUS II-L systems will be delivered with AIXTRON’s new ARGUS Topside Temperature Control (TTC) system. The new method eliminates temperature variation within each run and run-to-run, enabling unmatched production yields.

“This latest multiple tool order reflects FOREPI’s growth as a top-tier LED chip manufacturer. We are pleased to support this prized customer with our latest technology. Besides reactor size and design, we believe that successful in-situ measurement and control offer the greatest optimization potential because they provide a direct impact on yields,” said Dr. Christian Geng, general manager of AIXTRON Taiwan.

LEDs are projected to grow more than six-fold to nearly $100 billion and power conversion electronics to $15 billion over the next decade as the desire for energy efficiency drives adoption, says Lux Research. While the market opportunity is clear, the winning positions are still very much up for grabs, so making wise partnership and investment choices is critical.  

“A slew of developers are working on innovative materials and system architectures, targeting the primary challenges of cost reduction and manufacturability,” said Pallavi Madakasira, Lux Research Analyst and the lead author of the report titled, Winning the Jump Ball: Sorting Winners from Losers in LEDs and Power Electronics. “Many leading lights of the electronics industry are strong in these markets, but start-ups with novel technologies are looking to grab a share for themselves.  

Lux Research positioned the key developers of LEDs and power electronics materials, devices, and systems on the Lux Innovation Grid based on their technical Vvalue and business execution – companies that are strong on both axes reach the “dominant” quadrant. They also assessed each company’s maturity, and provided an overall Lux Take. Among their findings:

  • SiC players are dominant in power electronics. The “dominant” power electronics players wager mostly on SiC. Cree is a fully vertically integrated SiC device manufacturer, while other top leaders are experienced players from silicon power electronics like Infineon, Rohm Semiconductor and ST Microelectronics.
  • Cree, II-VI Wide Bandgap lead materials space. Cree is also “dominant” in materials, based on its development of SiC substrates. The only other company with a “dominant” rank is II-VI Wide Bandgap Group, an SiC wafer supplier with established relationships with power electronics and RF device manufacturers.
  • Six vie for dominance in LED. Cree is the leader in LEDs as well, the only firm that has successfully commercialized SiC-substrate-based LEDs at scale. Among other “dominant” firms, Nichia holds the most IP, while Samsung, Philips, and Osram Opto Semiconductors have all demonstrated GaN-on-silicon LEDs. GE Lighting does not have its own chip technology but its integration further down the value chain and its recent acquisition of fixture manufacturer Albeo make it a force to reckon with.

The report, titled Winning the Jump Ball: Sorting Winners from Losers in LEDs and Power Electronics, is part of the Lux Research Energy Electronics Intelligence service.

GT Advanced Technologies and Soitec , today announced a development agreement and a licensing agreement allowing GT to develop, manufacture and commercialize a high-volume, multi-wafer HVPE system to produce high-quality GaN epi layers on substrates used in the LED and other growth industries such as power electronics. The higher growth rates and improved material properties made possible by the HVPE system are expected to significantly reduce process costs while boosting device performance compared with the traditional MOCVD process. Initial pre-payment of the licensing fees as outlined in the agreement is already underway, but further specific terms were not disclosed.

GT will develop, manufacture and commercialize the HVPE system incorporating Soitec Phoenix Labs’ unique and proprietary HVPE technology including its novel and advanced source delivery system that is expected to lower the costs of precursors delivered to the HVPE reactor. The HVPE system will enable the production of GaN template sapphire substrates at scale. The expected target date for the commercial availability of the HVPE system is the second half of 2014.

“We have been working for more than 6 years on GaN epi processes and have created this breakthrough HVPE technology critical in producing high-quality and low cost GaN layers on sapphire substrates,” said Chantal Arena, VP and general manager of Soitec Phoenix Labs. “The development and license agreements we are announcing today with GT is the ultimate validation of this work and builds on the agreement we announced last year with Silian to integrate a HVPE-based technology on their sapphire. This allows Soitec to structure its LED lighting offer around differentiated technologies and industrial partners that includes materials and equipment. Soitec Phoenix Labs deep know-how in epitaxy technologies and GaN materials will be a key factor to enable GT to bring a revolutionary HVPE system to the market.”

“GT has a successful track record of delivering innovative equipment that has changed industries such as solar PV and LED,” said Tom Gutierrez, GT’s president and CEO. “Our decision to enter into the agreements with Soitec is the result of our extensive search for the right partner with the right technology to complement our equipment business as we diversify into new, high-value technologies that broaden our reach and bring winning solutions to the market. Soitec Phoenix Labs brings a high level of expertise and technical experience in GaN process know-how. When commercially available, we believe the new HVPE system will be a key element to further reduce LED device costs and help propel the industry to greater levels of competitiveness and growth.”

Soitec is an international manufacturing company, generating and manufacturing semiconductor materials. Soitec’s products include substrates for microelectronics and concentrator photovoltaic systems (CPV). Soitec has manufacturing plants and R&D centers in France, Singapore, Germany, and the United States.

GT Advanced Technologies Inc. is a technology company with crystal growth equipment and solutions for the global solar, LED and electronics industries.

Silicon nanocrystals have a size of a few nanometers and possess a high luminous potential. Scientists of Karlsruhe Institute of Technology (KIT) and the University of Toronto/Canada have now succeeded in manufacturing silicon-based light-emitting diodes (SiLEDs). They are free of heavy metals and can emit light in various colors.

Liquid-processed SiLEDs: By changing the size of the silicon nanocrystals, color of the light emitted can be varied. (Photo: F. Maier-Flaig, KIT/LTI)

Silicon dominates in microelectronics and photovoltaics industry, but has been considered unsuitable for light-emitting diodes for a long time. However, this is not true for nanoscopic dimensions: Minute silicon nanocrystals can produce light. These nanocrystals consist of a few hundred to thousand atoms and have a considerable potential as highly efficient light emitters, as was demonstrated by the team of Professor Uli Lemmer and Professor Annie K. Powell from KIT as well as Professor Geoffrey A. Ozin from the University of Toronto. In a joint project, the scientists have now succeeded in manufacturing highly efficient light-emitting diodes from the silicon nanocrystals.

So far, manufacture of silicon light-emitting diodes has been limited to the red visible spectral range and the near infrared.

“Controlled manufacture of diodes emitting multicolor light, however, is an absolutely novelty,” explains Florian Maier-Flaig, scientist of the Light Technology Institute (LTI) of KIT and doctoral student of the Karlsruhe School of Optics and Photonics (KSOP). KIT scientists specifically adjust the color of the light emitted by the diodes by separating nanoparticles depending on their size.

 “Moreover, our light-emitting diodes have a surprising long-term stability that has not been reached before,” Maier-Flaig reports.

The increased service life of the components in operation is due to the use of nanoparticles of one size only. This enhances the stability of the sensitive thin-film components. Short circuits due to oversized particles are excluded.

The development made by the researchers from Karlsruhe and Toronto is also characterized by an impressing homogeneity of the luminous areas. The KIT researchers are among the few teams in the world that know how to manufacture such devices.

“With the liquid-processed silicon LEDs that may potentially be produced on large areas as well as at low costs, the nanoparticle community enters new territory, the associated potentials of which can hardly be estimated today. But presumably, textbooks about semiconductor components have to be rewritten,” says Geoffrey A. Ozin, who is presently working as a KIT distinguished research fellow at KIT’s Center for Functional Nanostructures (CFN).

The SiLEDs also have the advantage that they do not contain any heavy metals. In contrast to cadmium selenide, cadmium sulfide or lead sulfide used by other groups of researchers, the silicon used by this group for the light-emitting nanoparticles is not toxic. Moreover, it is available at low costs and highly abundant on earth. Due to their many advantages, the SiLEDs will be developed further in cooperation with other partners.

Worldwide LED component market grows 9%

Strategies Unlimited has issued new figures since the first edition of this article. Solid State Technology now brings you updated figures and additional information on the worldwide LED market.

LED component revenue for lighting applications reached $3.11 billion in 2012, narrowly dethroning the large area display backlight segment at $3.06 billion, according to Strategies Unlimited, a market research firm covering the LED industry.  The worldwide market for LED components was $13.7 billion and is expected to grow to $15 billion in 2017, for a CAGR of 1.8%.

The total illumination market for 2012 is estimated at $14.52 billion. LED lighting includes LED replacement lamps and luminaires is estimated at $11.72 billion—an increase of 26% between 2011 and 2012—and it is forecast to grow at a CAGR of 12% over 2012-2017.

The 2012 estimate for revenues for the illumination market, not addressed by the LED replacement lamps and luminaires is $2.75 billion revenue.  These other applications include: decorative/festive/Christmas light strings; tube lights that go into many untraceable applications including signs; flexible tape and strips of LEDs sold in applications ranging from step lighting to lighting stairs to DIY cove lighting; and all other miscellaneous.

Commercial applications are the largest segment and grew the fastest—72%—in the LED lighting market followed by replacement lamps. Japanese market was the primary driver for the 22% growth in replacement lamp revenues from 2011 to 2012. The slower growing segments such as emergency and industrial lighting depend on the overall economic activity; entertainment lighting was a victim of slow down in European financial crisis, after the frenzy for the Olympics.

LEDs used in large display (TV and monitors) backlights also reached a new record at $3.06 billion in 2012. This is chiefly due to the success in penetrating the CCFL stronghold of the 32-inch TV. Low cost direct technology, also known as “chubby TV” technology because the TVs are thicker than edge-lit ones and narrows the price gap between CCFL and LED backlit TV to an insignificant level.  Both Samsung and LG have announced they will stop making CCFL TVs.

Chubby TVs will spread from 32 inches in both directions in size. It is expected to reach TVs 42 to 50 inches size in 2013-2014.  With drastic reduction in number of LEDs used and rapid price erosion, the large display market for LEDs is expected to decline to $1.7 billion in 2017.

The total market for LEDs in the automotive segment was $1.4 billion in 2012 and is projected to grow to $2.1 billion in 2017. The number of cars with LED headlights nearly doubled in 2012. Revenue for 2012 was $97 million and the five-year CAGR is projected to be 36%.

The number of cars with LED headlights nearly doubled in 2012. Revenue for 2012 was $97 million and the five-year CAGR is projected to be 36%.  Revenue derived from daytime running lights (DRL) grew 31% to $200 million in 2012.  DRL growth is expected to slow down as the penetration rate is forecast to reach 45% in 2017.  The total market for LEDs in the automotive segment was $1.4 billion in 2012, and is projected to grow to $2.1 billion in 2017.

While LED revenue from tablets grew 54% to $578 million, the overall mobile segment dropped 3%.  The drop in notebook backlight demand, the OLED success in smart phone display, and the general demand decline for other small and medium display will take the segment down to $958 million in 2017, for a 5 year CAGR of -7%.

Use of LEDs in signage and channel letters grew 7% to $1.7 billion in 2012.  Full-color signs contributed more than 80% of the revenue. The most popular pixel densities for indoor displays are expected to be 3mm and 4mm in 2013, meaning more LEDs will be needed.  The signage segment is expected to grow to $2.4 billion in 2017, for a CAGR of 7%. 

Breakdown of worldwide LED market by countryOn the supply side, 11 companies accounted for more than 72% of the LED market. Strategies Unlimited arrived at these figures after analyzing market demand as well as the supply-side activity of more than 54 LED component suppliers. The rank order of the top 11 suppliers in the LED market for 2012, by revenue of packaged LED components, is:

1. Nichia     

2. Samsung LED         

3. Osram Opto Semiconductors        

4. LG Innotek       

5. Seoul Semiconductor*       

6. Philips Lumileds*        

7. Cree         

8. TG      

9. Sharp       

10. Everlight*     

11. Lumens*

(*Companies have the same ranking when the difference in revenue is within the margin of error. Revenue includes sales of packaged LEDs of 30 lm/W or more.)

Samsung LED was absorbed into Samsung Electronics in 2012. By going vertical and successfully attacking the low cost direct TV market, LED sales soared at Samsung and at its chief supplier, Lumens. TG’s success in the tablet backlight market and the Japanese lighting market brought high growth to the company. Cree and Philips Lumileds rode the rise of LED lighting and achieved record revenues.

Chinese packaging companies grew from 6% of worldwide sales to 8%. Major consolidation is expected in China as the pricing war is forcing out many players. Taiwanese market share dropped from 19% to 15% as there is an increase of OEM packaging activities.  Only final sale is counted in this study.

The LED packaging industry is expected to grow modestly at a CAGR of 1.8% in the next five years. 2013 should see less severe price drops as excess capacity is slowly absorbed by the rise of lighting applications.  Consolidation—both vertical and horizontal—can help improve margins. 

Breakdown of worldwide LED market by technology

 

CRS Electronics Inc., a developer and manufacturer of LED lighting, today announced the appointment of Mr. Travis Jones to the position of Chief Executive Officer. Mr. Scott Riesebosch, founder and former CEO will assume the role of Chief Technology Officer.

Prior to joining CRS Electronics, Jones worked for Lighting Science Group as vice president of National Accounts where he created a new division that secured a record 60 new national accounts in 14 months. Before joining Lighting Science Group, Jones worked for some of the largest lighting companies in North America. While at Acuity Brands he served as vice president of sales and marketing in the Austin Division where he was responsible for a 52-person staff that managed 4 brands and 3 sales channels, leading them from $73MM to $100MM in revenue over two years. Jones is based in Texas where he serves as the Chairman of the Board of Directors for Lakehills Church in Cedar Park, Texas. He also serves on the board of directors for the Lakeland College Alumni Association in Sheboygan, Wisconsin, where he earned his B.A. in Philosophy and Business Administration.

"We are very excited to welcome Mr. Jones to the executive management team," said Mr. Chang Jiang Wu, executive chairman of CRS Electronics. "Mr. Jones has many years of experience in the LED lighting industry and has proven his ability to be an effective leader in establishing market strategies, growing revenue, and being responsible for achieving profitable results. Throughout his career in the lighting industry, Travis has repeatedly built successful sales teams with a proven track record of leadership, has always exceeded sales and profitability targets, and has a solid reputation in the lighting industry.”

Mr. Jones’ appointment is subject to receipt of the approval of the TSX Venture Exchange.

GaN on GaN LEDs by SoraaSoraa announced yesterday the next generation of its high external quantum efficiency GaN on GaN LEDs. As described in Appl. Phys. Lett. 101, 223509, Soraa’s new LED outperforms the best-documented LED laboratory result by Nichia Chemical Co. at current densities of 100 A/cm2 and beyond.

“The record breaking performance from our next generation of GaN on GaN LEDs is a credit to the extremely talented research and development team at Soraa, and a testament to the vision of our founder and GaN on GaN pioneer, Dr. Shuji Nakamura,” said Mike Krames, CTO of Soraa. “But what’s amazing is that we have just scratched the surface in terms of performance gains from our GaN on GaN LED technology.”

Soraa’s GaN on GaN LEDs handle significantly more current and emit ten times more light per unit area of LED wafer material than conventional LEDs made by depositing GaN layers on cheaper foreign substrates like sapphire, silicon carbide or silicon. The company’s GaN on GaN technology leverages the advantages of the native substrate, including over a thousand times lower crystal defect densities that allow reliable operation at very high current densities (the same principle that enabled Blu-ray laser diodes). In addition to superior crystal quality, the native substrate’s optical transparency and high electrical and thermal conductivity enable a very robust, simple LED design that delivers maximum performance. Another advantage of the GaN on GaN approach is that it enables considerable flexibility in the choice of crystal growth plane.

 “We firmly believe that GaN on GaN is the future for LEDs and we’ve developed a comprehensive intellectual property program and patent portfolio covering the technology to maintain our leadership position.” added Krames.

Soraa leveraged the advantages of its first generation GaN on GaN LEDs by introducing in 2012 the true full-visible-spectrum LED MR16 lamps—a superior alternative to 50-Watt halogen MR16 lamps. Soraa’s LED MR16 lamps have a CRI of 95 and R9 of 95 (higher than most halogen lamps) and compared to halogen lamps, produce no UV or IR; last up to 10 times as long; use 75 percent less energy; run cooler; produce a much more consistent and efficient beam; and are compatible with existing lamp fixtures and lighting infrastructure.

CoorsTek, one of the largest technical ceramics manufacturers, today announced introduction of aluminum nitride substrates. Ideal for the rapidly growing LED market and other markets where high heat dissipation is useful, these ceramic substrates boast a thermal conductivity of 170 W/m K.

CoorsTek AlN (aluminum nitride) ceramic substrates feature a very high dielectric strength, are a non-toxic alternative to BeO (beryllium oxide), and exhibit a thermal expansion coefficient similar to Si, GaN, and GaAs semiconductors.

“While we already offer an extensive line of ceramic substrates, our new high performance aluminum oxide substrates cover high heat dissipation applications,” says Andrew Golike, electronics general manager for CoorsTek, Inc.

Established in 1910, CoorsTek is one of the largest technical ceramics manufacturer in the world with over 40 facilities in the Americas, Europe, and Asia.